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All surfaces must be dry, clean and free from oils, dirt or other contaminants. FlexRock products should not be applied over peeling paint, chalking surfaces or other areas that inhibit adhesion to a solid surface. Some surfaces may require pressure washing, broom sweeping, brushing or sweep blasting to remove deleterious materials.
In some cases the Fill Kote product may be applied to existing brick walls which are exhibiting some areas of loose mortar. As the product adheres to the brick joints, loose mortar will be hidden and reinforced. In these cases, dust, scale or other materials which create films should be removed prior to application of any of the FlexRock products.
New construction requires proper fastening of all sheathing panels. We recommend screws' being used at the panel joints although, this is not a requirement. If nails are used, they must be no smaller than 8d ring shank when fastening plywood or OSB to a stud wall. Fasteners should be spaced no farther than 12" O.C. and should always be within 2" at all corners. All nails must be secure in the framing. Loose nails or screws are not acceptable. All nails or fasteners must be driven flush or below flush. All surfaces should be inspected for delaminating strands, laminates or splintering of the sheathing of any kind.
BC grade exterior plywood is recommended for plywood applications. Although CDX can be used, knot holes and other imperfections must be filled. It is doubtful that the savings on the sheathing will offset the expense of more preparation. Any splintering or blisters should be removed prior to the installation of any FlexRock product.
 All sheathing should be fastened tightly against the framing, leaving no areas where sheathing may have a spring action. This is especially important at all joints. Areas of severe high low in the panel joints should be sanded flush if additional fastening does not flush the surface. The photo at right shows a metal building front being transformed with an attractive stone look. All of the columns and arches are built from exterior grade plywood and pine framing. The Base Kote System should be applied as soon as possible after the sheathing is installed to reduce water damage and warpage to the sheathing. The Base Kote product should not be applied to a wet substrate.
Pictured left is an example of a would-be short cut. The plywood has small splits showing through a thin single application of the FlexRock Base Kote. This issue was caused by several days of rain making the plywood swell, and then arid weather allowed it to dry. Although there are installations direct to wood which have fabric on the joints only and have lasted for several years, we can no longer approve this type of installation. By installing the FlexRock Polyester to all areas, applicators are forced to apply the correct amount of product for the embed process.
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